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This study consists of three self-standing parts, each dealing with a different aspect of design of composite steel-concrete flexural members. The first part deals with a new type of shear connection in composite joists. Composite steel-concrete flexural members have increasingly become popular in design and construction of floor systems, structural frames, and bridges. A particularly popular system features composite trusses (joists) that can span large lengths and provide empty web space for installation of typical utility conduits. One of the prominent problems with respect to composite joists has been the installation of welded shear connection due to demanding welding requirements and the need for significant welding equipment at the job site. This part of the study presents a new type of shear connection developed at Virginia Tech— standoff screws. Results of experimental and analytical research are presented, as well as the development of a recommended design methodology. The second part deals with reliability of composite beams. Constant research advances in the field of composite steel-concrete beam design have resulted in numerous enhancements and changes to the American design practice, embodied in the composite construction provisions of the AISC Specification (AISC 1999). Results of a comprehensive reliability study of composite beams are presented. The study considers specification changes since the original reliability study by Galambos et al. (1976), considers a larger database of experimental data, and analyses recent proposals for changes in design of shear connection. Comparison of three different design methods is presented based on a study of 15,064 composite beam cases. A method to consider effect of degree of shear connection on strength reduction factor is proposed. Finally, while basic analysis theories between the two are similar, requirements for determining the strength of composite beams in Eurocode 4 (CEN 1992) and 1999 AISC Specification (AISC 1999) differ in many respects. This is particularly true when considering the design of shear connections. This part of the dissertation explores those differences through a comparative step-by-step discussion of major design aspects, and accompanying numerical example. Several shortcomings of 1999 AISC Specification are identified and adjustments proposed. / Ph. D.

Strain-hardening cement-based composites (SHCC) are a special class of fiber-reinforced concrete which develop multiple, fine cracks when subjected to increasing tensile loading, reaching strain capacities of up to several percent. The tensile behavior of SHCC is a result of a purposeful material design accounting for the mechanical and physical properties of the cementitious matrix, of the reinforcing fibers and of their interaction. The exceptionally high energy dissipation through inelastic deformations before reaching tensile strength makes SHCC suitable for manufacturing or strengthening of structural elements which may be subjected to impact loading. However, the tensile behavior of SHCC is highly strain rate dependent, both in terms of tensile strength and strain capacity. The different strain rate sensitivities of the constitutive phases of SHCC (matrix, fiber and interfacial bond) lead to disproportionate dynamic alteration of their mechanical properties under increasing strain rates and, consequently, to an impairment of the micromechanical balance necessary for strain-hardening and multiple cracking. Thus, high energy dissipation under impact loading can only be ensured through a targeted material design. This work presents a series of mechanical experiments at different strain rates and different scales of investigation with the goal of developing a qualitative and quantitative basis for formulating material design recommendations for impact resistant SHCC. Three different types of SHCC were investigated, consisting of two types of polymer fibers (polyvinyl-alcohol and high-density polyethylene) and cementitious matrices (normal-strength and high-strength). Uniaxial tension experiments were performed on SHCC specimens and on non-reinforced matrix specimens with different testing setups at strain rates ranging from 10-4 to 150 s-1. Besides the measured mechanical properties, special attention was paid to the crack patterns and the condition of fracture surfaces. Additionally, micro-scale investigations were performed to quantify the strain rate dependent changes in the mechanical behavior of individual component phases, i.e., matrix, fibers and fiber-matrix bond. The results obtained from the micromechanical investigations were used in an analytical model for crack bridging. The model links the micromechanical parameters and their strain rate sensitivities to the single-crack opening behavior under increasing displacement rates, making it useful for material design purposes. If given an extensive experimental basis for the fracture mechanical properties of the non-reinforced cementitious matrices, the model can be extended for predicting the strain capacity (multiple cracking) of SHCC under different strain rates. / Die hochduktilen Betone (Engl.: Strain-Hardening Cement-based Composites – SHCC) bilden eine besondere Klasse von Faserbetonen, die eine multiple Rissbildung unter zunehmenden Zugspannungen aufweisen, was zu einer sehr hohen Bruchdehnung führt. Das dehnungsverfestigende, hochduktile Zugverhalten der SHCC wird durch eine gezielte Materialentwicklung erreicht, die die mechanischen und physikalischen Eigenschaften der zementgebundenen Matrizen, der Kurzfasern und deren Zusammenwirkung berücksichtigt. Das außergewöhnliche Energieabsorptionsvermögen der SHCC durch plastische Verformungen vor dem Erreichen der Zugfestigkeit qualifiziert diese Verbundwerkstoffe für die Herstellung oder Verstärkung von Bauteilen, die Impaktbeanspruchungen ausgesetzt sein könnten. Jedoch weisen SHCC sowohl bezüglich deren Zugfestigkeit als auch deren Dehnungskapazität ein ausgeprägtes dehnratenabhängiges Verhalten auf. Unter zunehmenden Dehnraten führen die unterschiedlichen Dehnratensensitivitäten der gestaltenden Phasen von SHCC (Matrix, Faser und deren Verbund) zur Beeinträchtigung des mikromechanischen Gleichgewichts, welches für die Dehnungsverfestigung und multiple Rissbildung erforderlich ist. Eine hohe Energiedissipation unter Impaktbeanspruchungen kann deshalb nur durch eine gezielte Materialentwicklung der SHCC hinsichtlich deren Verhaltens unter hohen Dehnraten gewährleistet werden. Die vorliegende Arbeit umfasst eine Reihe von experimentellen Untersuchungen mit verschiedenen Dehnraten und an unterschiedlichen Betrachtungsebenen, mit dem Ziel eine qualitative und quantitative Basis für Empfehlungen zur Materialentwicklung von Impakt-resistenten SHCC zu schaffen. Drei verschiedene SHCC-Zusammensetzungen wurden untersucht. Die Referenz-Zusammensetzung aus einer normalfesten zementgebundenen Matrix und Polyvinyl-Alkohol-Kurzfasern wurde mit zwei unterschiedlichen SHCC verglichen (hochfest und normalfest), die mit Kurzfasern aus hochdichtem Polyethylen bewehrt wurden. Einaxiale Zugversuche wurden an SHCC-Proben und unbewehrten Matrix-Proben mit verschiedenen Prüfvorrichtungen bei Dehnraten von 10-4 bis 150 s-1 durchgeführt. Zusätzlich zu den gemessenen mechanischen Eigenschaften wurden die Rissbildung und die Bruchflächen detailliert untersucht. Darüber hinaus wurden mikromechanische Untersuchungen durchgeführt, um die Dehnratensensitivität der einzelnen Phasen, d.h. Matrix, Faser und deren Verbund zu beschreiben. Die aus den mikromechanischen Untersuchungen erzielten Ergebnisse wurden als Eingangswerte in einem analytischen Einzelriss-Modell verwendet. Das entwickelte Modell verbindet die mikromechanischen Parameter und deren Dehnratenabhängigkeit mit dem Rissöffnungsverhalten von SHCC bei zunehmenden Verschiebungsraten. Das macht es vorteilhaft für Materialentwicklungszwecke. Das Modell kann für die Vorhersage der Dehnungskapazität von SHCC bei diversen Dehnraten weiterentwickelt werden, wenn eine umfassende experimentelle Basis für die bruchmechanischen Eigenschaften der Matrizen vorliegt.

Thesis (M. Tech. (Engineering: Mechanical)) -- Central University of Technology, Free State, / The Centre for Rapid Prototyping and Manufacturing (CRPM) at the Central University of Technology, Free State (CUT) manufactures implants using Electro Optical Systems (EOS) titanium Ti-6Al-4V alloy powder (further referred to as EOS Ti64 powder) by means of Direct Metal Laser Sintering (DMLS) process on the EOSINT M 270 machine. For this reason, there is a need to characterise and acquire knowledge of the basic properties of direct metal laser sintered EOS titanium Ti-6Al-4V alloy samples (further referred to as DMLS Ti64 samples) under static tensile loading in order to provide the CRPM with engineering design data. The first objective of this Master’s study is to acquire the characteristics of EOS Ti64 powder in order to ascertain its suitability in the DMLS process. Secondly, the study aims to assess tensile properties and elastic constants of DMLS Ti64 samples produced from the set process parameters of EOSINT M 270 machine. Thirdly, it is to investigate microstructures of DMLS Ti64 samples subjected to different heat treatment techniques which will eventually assist in the determination of a suitable heat treatment technique that will yield higher ductility. Finally, the study aims to validate the static behaviour of DMLS Ti64 samples subjected to the static tensile loading up to a yield point in order to determine failure due to yielding. The samples were manufactured at CRPM Bloemfontein. The metallographic examinations, heat treatment and the determination of mechanical properties were done at the CSIR in Pretoria. Optical Microscope (OM) and Scanning Electron Microscope (SEM) were used to determine microstructures of DMLS Ti64 samples while Energy Dispersive X-Ray (EDX) analyses were performed using SEM. The samples were heat treated at temperatures of 700, 1000 and 1100°C respectively, and subsequently either cooled with the furnace, air or were water quenched. The mechanical property tests included tensile, hardness and determination of elastic constants. The static behaviour of DMLS Ti64 samples under static tensile load up to a yield point was predicted and verified using ABAQUSTM Finite Element Analysis (FEA). The stress-strain curves from ABAQUSTM were interpreted using MDSolid program. The point of interest was Von Mises yield stress at 0.2% offset, in order to determine failure due to yielding. EOS Ti64 powder particles were spherical in shape and the alpha and alpha+beta phases were identified. As-laser sintered samples possess a very fine and uniform alpha case with islands of martensitic plates; samples were brittle and showed low levels of ductility with an average elongation of 2.6% and an area reduction of 3.51%. Ultrasonic test results showed that DMLS Ti64 samples have Young’s modulus of 115 GPa, Shear modulus of 43 GP, a bulk modulus of 109 GPa and Poisson’s ratio of 0,323 while the density was 4.4 g/cm3. Slow cooling of DMLS Ti64 samples from 1000 and 1100oC resulted in a microstructure constituted more by the alpha phase of lower hardness than those from 700oC and as-laser sintered samples. High hardness was obtained by water quenching. The water quenched samples showed martensitic transformation and high hardness when compared to furnace cooled samples. Beta annealing tailored a microstructure of as-laser sintered samples into a lamellar structure with different lath sizes as per cooling rate. Beta annealing improved ductility levels up to 12.67% elongation for samples furnace cooled for 4 hours and even higher to 18.11% for samples furnace cooled for 34 hours, while area reduction increased to 25.94% and 33.39%, respectively. Beta annealing conversely reduced yield strength by 19.89% and ultimate tensile strength was reduced by 23.66%. The calculated maximum Von Mises stresses found were similar to the FEA interpreted results. The average percentage error, without the stress concentration factor, was approximately 8.29%; with the stress concentration factor included, it was 0.07%. The small reaction forces induced in both x-axis and z-axis contributed to this error of 0.07% between the calculations and ABAQUSTM FEA results. Samples that were not heat treated fell outside the Von Mises criterion and failed due to yielding. This justified the brittleness found in the tensile test results where elongation and area reduction were 2.6% and 3.51% respectively. However, all samples that were heat treated fell within the Von Mises criterion. The objectives of this study were achieved; the mechanical properties were similar to those of standard specification for wrought annealed Ti-6Al-4V alloy for surgical implant applications and EOS GmbH manufacturer’s material data sheet. DMLS Ti64 samples must be beta annealed in order to attain higher levels of ductility. A recommendation was made to further investigate the effect of heat treatment on the other mechanical properties. Furthermore, detailed results of basic properties of DMLS Ti64 samples are provided in the appendices in chart format and were written on a CD disc.

La ductilité et la capacité à dissiper de l'énergie sont deux qualités très importantes pour les éléments structuraux des structures situées dans les régions sismiques comme l'est du Canada. Soulignons que Montréal occupe la deuxieme place en ce qui a trait au risque sismique au Canada. De plus, la réduction des coûts de maintenance des infrastructures est un sujet d'intérêt pour les propriétaries alors que ces derniers doivent en tout temps garantir la sécurité des usagers. Or, le béton renforcé avec des fibres synthétiques semble être un matériau qui remplit ces caractéristiques. Pourtant, son utilisation est actuellement limitée aux éléments non structuraux ou structuraux mais non principaux. Afin de généraliser l'utilisation du béton fibre dans le domaine structural, il faut continuer à produire et à analyser des données expérimentales qui permettront de valider et d'améliorer les prescriptions de design et les modèles analytiques actuels pour la conception des éléments en béton armé avec des fibres dans les zones sismiques. Dans ce contexte, six poteaux circulaires à grande-échelle ont été testés sous une charge axiale constante (25% de Agf'c) et en flexion cyclique. Trois poteaux ont été confectionnés en béton normal (BN) et les trois autres en béton renforcé avec des fibres synthétiques (BRFS). La résistance à la compression du béton spécifiée à 28 jours pour les spécimens était de 30 MPa. Le volume de fibres synthétiques en polypropylène-polyéthylène utilisé a été de 1%. Les trois poteaux en BN étaient renforcés par une armature transversale constituée d'une spirale ayant un pas de 42, 75 et 100 mm respectivement. Ces trois spécimens ont été comparés avec des spécimens similaires en BRFS. Les résultats montrent que la présence des fibres synthétiques dans la matrice de béton améliore le comportement ductile et la capacité a dissiper de l'énergie des spécimens. Il a été observé que cette amélioration n'est pas directement proportionnelle à la quantité d'armature transversale. Toutefois, l'utilisation du béton fibre semble rendre possible une réduction de l'armature transversale tout en conservant un aussi bon sinon un meilleur comportement.

Ce présent travail concerne les aspects de la réparation et du renforcement des ouvrages utilisant des matériaux composites et plus particulièrement, il traite le cas des poutres en béton endommagées. La méthode de renforcement des ouvrages en béton par collage de matériaux composites est une pratique qui connaît actuellement un essor important. Dans cette optique, on propose d’apporter une contribution à l’analyse du comportement des poutres endommagées en béton par matériaux composites. La nouvelle méthode de renforcement interne NSM (Near Surface Mounted) consiste en l’insertion de bandes de Polymères Renforcées de Fibres (PRF) dans des engravures préparées préalablement dans le béton d'enrobage des surfaces tendues, remplies de résines époxydiques pour fixation. Pour construire un système renforcé de NSM efficace, les armatures en PRF doivent être en mesure de transférer ses efforts longitudinaux développés à l'élément de flexion en béton armé afin d'assurer l’action du composite, avec une compatibilité de déformation des matériaux. Les spécimens testés sont composés de poutres coutres avec une section rectangulaire de (100 mm x180 mm) et une longueur de 1300 mm renforcés avec PRFC-NSM. D’autres spécimens de poutres rectangulaires ont été testés avec une section de 200 mm x 400 mm et une longueur de 2300 mm, les renforts en PRF utilisés sont des plats ou des joncs. Les paramètres étudiés dans ce travail concernent la classe de résistance en compression, le taux de renfort, le type de composite et le degré d’endommagement. L’étude expérimentale sur le comportement des poutres endommagées puis renforcées sollicitées en flexion 4 points a dévoilé beaucoup de critères de performances en termes de ductilité, de rigidité et de capacité portante. Une modélisation analytique a été menée afin de comparer les réponses moment-courbure analytiques avec celles obtenues expérimentalement. Une fois cette modélisation validée, l’approche analytique a été couplée avec la méthode des plans d’expériences dans le but d’évaluer l’influence de différents paramètres et leurs interactions tels que le type de renfort (carbone, Joncs, aramide), le taux d’armatures passives et de renfort et la classe de résistance sur les réponses concernant la capacité portante et la ductilité des poutres renforcées. / This work deals with aspects of repair and reinforcement of structures and in particular, it deals with the case of damaged concrete beams. The method of reinforcing concrete structures by adhesive bonding of composite materials is a practice which is currently undergoing a major expansion. In this context, we propose to contribute to the analysis of the behavior of damaged concrete beams by composite materials. The new NSM (Near Surface Mounted) internal reinforcement method consists of the insertion of carbon fiber reinforced polymer (PRFC) strips in pre-prepared etchings in the encapsulation concrete of stretched surfaces filled with epoxy resins for fixing. To build an effective NSM reinforced system, FRP reinforcements must be able to transfer its developed longitudinal forces to the reinforced concrete flexure element to ensure the action of the composite with material deformation compatibility. The specimens tested consist of beams with a rectangular section (100 mm x 180 mm) and a length of 1300 mm reinforced with PRFC-NSM. Other specimens of rectangular beams were tested with a section of 400 mm x 800 mm and a length of 2300 mm, the FRP reinforcements used were either plates or rods. The parameters studied in this work concern the strength of the concrete, the reinforcement rate, the type of composite, the degree of damage. The experimental study on the behavior of damaged beams, then reinforced and subjected to bending, revealed many performance criteria in terms of ductility, stiffness and bearing capacity. Analytical modeling coupled with the experimental design method was carried out in order to evaluate the responses of the beams tested according to the interaction of the different parameters such as the reinforcement type (carbon, joncs, aramid), the Passive and reinforcement rates and strength class of reinforced beams.

Friction Stir Processing (FSP) is a promising thermomechanical technique that is used to modify the microstructure of metals locally, and thereby locally improve mechanical properties of the material. FSP uses a simple and inexpensive tool, and has been shown to eliminate pores and also reduce the sizes of intermetallics in aluminum alloys. This is of great interest for research on solidification, production and performance of aluminum alloy castings because FSP can enhance the structural quality of aluminum casting significantly by minimizing the effect of those structural defects. In the literature, there is evidence that the effectiveness of FSP can change with tool wear of the tool used. Therefore, a study was first conducted to determine the effect of FSP time on the tool life and wear in 6061-T6 extrusions. Results showed the presence of two distinct phases in the tool life and wear. Metallographic analyses confirmed that wear in Phase I was due to fracture of the threads of the tool and Phase II was due to regular wear, mostly without fracture. Moreover, built-up layers of aluminum were observed between threads. The microhardness profile was found to be different from those reported in the literature for 6061-T6, with Vickers hardness increasing continuously from the the stir zone to the base material. To investigate the degree of effectiveness of FSP in improving the structural quality of cast A356 alloys, ingots with different quality (high and low) were friction strir processed with single and multiple passes. Analysis of tensile test results and work hardening characteristics showed that for the high quality ingot, a single pass was sufficient to eliminate the structural defects. Subsequent FSP passes had no effect on the work hardening characteristics. In contrast, tensile results and work hardening characteristics improved with every pass for the low quality ingot, indicating that the effectiveness of FSP was dependent on the initial quality of the metal. The evolution of microstructure, specifically the size and spacing of Silicon (Si) eutectic particles, was investigated after friction stir processing of high quality A356 castings with single and multiple passes. Si particles were found to coarsen with each pass, which was in contrast with previous findings in the literature. The nearest neighbor distance of Si particles also increased with each FSP pass, indicating that microstructure became progressively more homogeneous after each pass. In the literature, the improvement observed after FSP of Al-Si cast alloys was attributed to the refinement of Si particles. Tensile data from high quality A356 ingot showed that there was no correlation between the size of Si particles and ductility. To the author’s knowledge, this is the first time that the absence of a correlation between Si particle size and ductility has been found.

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